Hydraulic Systems

Hydraulic Fundamentals
 Hydraulic systems are
everywhere from:
 Large excavation
equipment
 Steering in your car
 Shocks
 Power trains
Hydraulic Fundamentals
 Using liquids to transfer
force
 They conform to their
container
 Practically incompressible
 Apply pressure in all
directions
 Flow in any direction
through lines and hoses.
Hydraulic Fundamentals
 Liquids for all practical
purposes are incompressible.
 When a substance is
compressed it takes up
space. A liquid does not
do this even under large
pressures.
 The space any substance
occupies is called
“displacement”.
Hydraulic Fundamentals

 Gases are compressible

 When a gas is compressed
it takes up less space and
its displacement is less.
For this reason liquids are
best used for hydraulic
systems.
Hydraulic Fundamentals
 Hydraulics doing work.
 Pascal’s law – “ Pressure exerted on a confined liquid is transmitted
undiminished in all directions and acts as a equal force on all equal
areas.”
 Thus a force exerted on any part of a confined liquid the liquid will
transmit that force (pressure) in all directions within the system.
Hydraulic Fundamentals
 Hydraulics doing work.
 In this example a 500 pound
force acting upon a piston
with a 2 inch radius creates a
pressure of 40 psi on the
fluid.
 This same liquid with a
pressure of 40 psi acting on a
piston with a 3 inch radius
can support 1130 pounds.
Hydraulic Fundamentals
 Pascal’s Law
 To understand how this works we must understand a very simple but
fundamental formula.
 To find one of the three areas two of the others must be known.
 Force – The push or pull acting on a body usually expressed in
pounds.
 Pressure – The force of the fluid per unit area. Usually expressed in
pounds per square inch or psi.
 Area – A measure of surface space. Usually calculated in square
inches.
 To calculate the area of a circle use the formula Area = Pi (3.14) x
radius squared.
 Ex: For a 2” radius piston A=3.14x(2”x2”) or A= 12.5 sq. in.
Hydraulic Fundamentals

 Pascal’s Law
 With the knowledge of the
surface area it is possible to
determine how much system
pressure will be required to lift
a given weight.
 The pressure needed for a 500
pound given weight is
calculated with the formula
 Pressure = Force ÷ Area
 P = 500lbs ÷ 12.5 Sp. In.
 P = 40 psi
Components of a hydraulic system

Components Example of a hydraulic system

 Reservoir
 Pump
 Actuators
 Accumulator
 Strainers & Filter
 Pipes
 Control valves
Components of a hydraulic system : Pump
 Hydraulic pumps supply
fluid to the components in
the system. Pressure in the
system develops in
reaction to the load.
Hence, a pump rated for
5,000 psi is capable of
maintaining flow against a
load of 5,000 psi.
 Hydraulic pumps convert mechanical energy from a
prime mover (engine or electric motor) into hydraulic
(pressure) energy.
 The pressure energy is used then to operate an actuator.
 Pumps push on a hydraulic fluid and create flow.

Pump Classifications:
 All pumps create flow. They operate on the displacement
principle.
 Pumps that discharge liquid in a continuous flow are
nonpositive-displacement type.
 Pumps that discharge volumes of liquid separated by
periods of no discharge are positive-displacement type.
Nonpositive-Displacement Pumps.
 With this pump, the volume of liquid
delivered for each cycle depends on
the resistance offered to flow.
 A pump produces a force on the liquid
that is constant for each particular
speed of the pump. Resistance in a
discharge line produces a force in the
opposite direction.
 When these forces are equal, a liquid
is in a state of equilibrium and does
not flow.
 If the outlet of a nonpositive-
displacement pump is completely
closed, the discharge pressure will
rise to the maximum for a pump
operating at a maximum speed.
 A pump will churn a liquid and
produce heat. Figure 3-1 shows a
nonpositive-displacement pump. A
water wheel picks up the fluid and
moves it.
Positive-Displacement Pumps.
 With this pump, a definite volume
of liquid is delivered for each cycle
of pump operation, regardless of
resistance, as long as the capacity
of the power unit driving a pump is
not exceeded.
 If an outlet is completely closed,
either the unit driving a pump will
stall or something will break.
 Therefore, a positive-displacement-
type pump requires a pressure
regulator or pressure-relief valve in
the system.
 Figure 3-2 shows a reciprocating-
type, positive-displacement pump.
GEAR PUMPS:
a. External. Figure 3-6 shows the operating principle of an external gear pump.
 It consists of a driving gear and a driven gear enclosed in a closely fitted housing. The
gears rotate in opposite directions and mesh at a point in the housing between the
inlet and outlet ports.
 As the teeth of the two gears separate, a partial vacuum forms and draws liquid
through an inlet port into chamber A. Liquid in chamber A is trapped between the teeth
of the two gears and the housing so that it is carried through two separate paths
around to chamber B. As the teeth again mesh, they produce a force that drives a
liquid through an outlet port.
VANE PUMPS:
 In a vane-type pump, a slotted rotor splined to a drive shaft rotates between closely
fitted side plates that are inside of an elliptical- or circular-shaped ring.
 Polished, hardened vanes slide in and out of the rotor slots and follow the ring contour
by centrifugal force.
 Pumping chambers are formed between succeeding vanes, carrying oil from the inlet
to the outlet. A partial vacuum is created at the inlet as the space between vanes
increases. The oil is squeezed out at the outlet as the pumping chamber's size
decreases.
 The normal wear points in a vane pump are the vane tips and a ring's surface, the
vanes and ring are specially hardened and ground. A vane pump is the only design
that has automatic wear compensation built in. As wear occurs, the vanes simply slide
farther out of the rotor slots and continue to follow a ring's contour. Thus efficiency
remains high throughout the life of the pump.
Unbalanced Vane Pumps:Unbalanced
design, (Figure 3-9), a cam ring's shape
is a true circle that is on a different
centerline from a rotor's.
• Pump displacement depends on how far
a rotor and ring are eccentric.
• The advantage of a true-circle ring is
that control can be applied to vary the
eccentricity and thus vary the
displacement.
• A disadvantage is that an unbalanced
pressure at the outlet is effective against
a small area of the rotor's edge, imposing
side loads on the shaft.
PISTON PUMPS:
 Piston pumps are either radial or axial.
a. Radial. In a radial piston pump (Figure 3-14), the pistons are arranged like wheel spokes in a
short cylindrical block.
 A drive shaft, which is inside a circular housing, rotates a cylinder block. The block turns on a
stationary pintle that contains the inlet and outlet ports.
 As a cylinder block turns, centrifugal force slings the pistons, which follow a circular housing.
 A housing's centerline is offset from a cylinder block's centerline. The amount of eccentricity
between the two determines a piston stroke and, therefore, a pump's displacement.
 Controls can be applied to change a housing's location and thereby vary a pump's delivery
from zero to maximum.
Components of a hydraulic system :
Reservoir
 A reservoir stores a liquid that is
not being used in a hydraulic
system. It also allows gases to
expel and foreign matter to settle
out from a liquid
Reservoir : Construction
 A properly constructed reservoir should be able to dissipate heat
from the oil, separate air from the oil, and settle out contaminates
that are in it.
 Reservoirs range in construction from small steel stampings to large
cast or fabricated units.
 The large tanks should be sandblasted after all the welding is
completed and then flushed and steam cleaned. Doing so removes
welding scale and scale left from hot-rolling the steel)
 The inner surface then should be sealed with a paint compatible with
the hydraulic fluid. Non bleeding red engine enamel is suitable for
petroleum oil and seals in any residual dirt not removed by flushing
and steam cleaning.
Reservoir : shape
• It should be high and narrow rather
than shallow and broad.
• The oil level should be as high as
possible above the opening to a
pump's suction line.
• This prevents the vacuum at the
line opening from causing a vortex
or whirlpool effect, which would
mean that a system is probably
taking in air.
• Aerated oil will not properly
transmit power because air is
compressible. Aerated oil has a
tendency to break down and lose
its lubricating ability.
Reservoir : Size
 Reservoir sizes will vary. However, a reservoir must be large enough so
that it has a reserve of oil with all the cylinders in a system fully extended.
 An oil reserve must be high enough to prevent a vortex at the suction line's
opening. A reservoir must have sufficient space to hold all the oil when the
cylinders are retracted, as well as allow space for expansion when the oil is
hot.
 Example:A common-size reservoir on a mobile machine is a 20- or 30-
gallon tank used with a 100-GPM system.
 A large-size tank is highly desirable for cooling. The large surface
areas exposed to the outside air transfer heat from the oil. Also, a large tank
helps settle out the contaminates and separates the air by reducing
recirculation
Reservoir : Location
 Most mobile equipment reservoirs are located above the pumps. This
creates a flooded-pump-inlet condition. This condition reduces the
possibility of pump cavitation-a condition where all the available space is
not filled and often metal parts will erode. Flooding the inlet also reduces
the vortex tendency at a suction pipe's opening.
 A reservoir's location affects heat dissipation. Ideally, all tank walls should
be exposed to the outside air. Heat moves from a hot substance to a cold
substance; heat transfer is greatest when there is a large temperature
difference. Reservoirs that are built into front-end loader arms are very
effective in transferring heat
Reservoir : VENTILATION AND
PRESSURIZATION
 Most reservoirs are vented to the atmosphere. A vent opening allows
air to leave or enter the space above the oil as the level of the oil
goes up or down.
 This maintains a constant atmospheric pressure above the oil.
 A reservoir filter cap, with a filter element, is often used as a vent.
 Some reservoirs are pressurized, using a simple pressure-control
valve rather than a vented one.
 A pressure-control valve automatically lets filtered air into a tank but
prevents air release unless the pressure reaches a preset level.
 A pressurized reservoir takes place when the oil and air in a tank
expand from heat
Strainers
 To keep hydraulic components
performing correctly, the
hydraulic liquid must be kept as
clean as possible. (Foreign
matter and tiny metal particles).
Strainers, filters, and magnetic
plugs are used to remove
foreign particles from a
hydraulic liquid and are
effective as safeguards against
contamination
Strainers (contd..)
 A strainer is the primary filtering system that removes large particles
of foreign matter from a hydraulic liquid. (Screening action).
 A strainer usually consists of a metal frame wrapped with a fine-
mesh wire screen or a screening element made up of varying
thicknesses of specially processed wire.
 Figure 2-12 shows a strainer in three possible arrangements for use
in a pump inlet line. If one strainer causes excessive flow friction to a
pump, two or more can be used in parallel. Strainers and pipe fittings
must always be below the liquid level in the tank.
Filter
 A filter removes small foreign particles from a hydraulic fluid and is
most effective as a safeguard against contaminants.
 Filters are located in a reservoir, a pressure line, a return line, or in
any other location where necessary. They are classified as full flow
or proportional flow.
Accumulators
 Like an electrical storage battery, a hydraulic accumulator stores
potential power, in this case liquid under pressure, for future
conversion into useful work.
 This work can include operating cylinders and fluid motors,
maintaining the required system pressure in case of pump or power
failure, and compensating for pressure loss due to leakage.
 Accumulators can be employed as fluid dispensers and fluid barriers
and can provide a shock-absorbing (cushioning) action.  
 Example:Accumulators are used mainly on the lift equipment to
provide positive clamping action on the heavy loads when a pump's
flow is diverted to lifting or other operations.
 An accumulator acts as a safety device to prevent a load from being
dropped in case of an engine or pump failure or fluid leak.
 On lifts and other equipment, accumulators absorb shock, which
results from a load starting, stopping, or reversal
Types of accumulators
 Spring loaded
 Bag type
 Piston type
Spring type accumulator
 It uses the energy stored in
springs to create a constant force
on the liquid contained in an
adjacent ram assembly.
 Figure 2-15 shows two spring-
loaded accumulators.
 The load characteristics of a
spring are such that the energy
storage depends on the force As liquid under pressure enters
required to compress a spring.
the ram cylinder, causing a spring
 The free (uncompressed) length of to compress, the pressure on the
a spring represents zero energy liquid will rise because of the
storage.As a spring is compressed increased loading required to
to the maximum installed length, a compress the spring.
minimum pressure value of the
liquid in a ram assembly is
established.
Bag type accumulator
 This accumulator (Figure 2-16)
consists of a seamless, high-
pressure shell, cylindrical in
shape, with domed ends and a
synthetic rubber bag that
separates the liquid and gas
(usually nitrogen) within the
accumulator.
 The bag is fully enclosed in the
upper end of a shell. The gas
system contains a high-pressure
gas valve. The bottom end of the The bag is larger at the top and
shell is sealed with a special plug tapers to a smaller diameter at the
assembly containing a liquid port bottom. As the pump forces liquid into
and a safety feature that makes it the accumulator shell, the liquid
impossible to disassemble the presses against the bag, reduces its
accumulator with pressure in the volume, and increases the pressure,
system. which is then available to do work
Piston type accumulator
 This accumulator consists of a
cylinder assembly, a piston
assembly, and two end-cap
assemblies. The cylinder
assembly houses a piston
assembly and incorporates
provisions for securing the end-
cap assemblies.
 An accumulator contains a free-
floating piston with liquid on one
side of the piston and precharged
air or nitrogen on the other side
(Figure 2-17).
 An increase of liquid volume
decreases the gas volume and
increases gas pressure, which
provides a work potential when
the liquid is allowed to discharge
Hydraulic Actuators
 A hydraulic actuator receives pressure energy and converts it to
mechanical force and motion.
 An actuator can be linear or rotary.
 A linear actuator gives force and motion outputs in a straight line. It
is more commonly called a cylinder but is also referred to as a ram,
reciprocating motor, or linear motor.
 A rotary actuator produces torque and rotating motion. It is more
commonly called a hydraulic motor or motor.
Cylinders
 A cylinder is a hydraulic actuator
that is constructed of a piston or
plunger that operates in a
cylindrical housing by the action of
liquid under pressure.
 Figure 4-1 shows the basic parts of
a cylinder.
 A cylinder housing is a tube in
which a plunger (piston) operates.
 In a ram-type cylinder, a ram
actuates a load directly. In a piston
cylinder, a piston rod is connected
to a piston to actuate a load.
 An end of a cylinder from which a
rod or plunger protrudes is a rod
end. The opposite end is a head
end. The hydraulic connections are
a head-end port and a rod-end port
(fluid supply).
a. Single-Acting Cylinder. This
cylinder (Figure) only has a head-
end port and is operated
hydraulically in one direction.
• When oil is pumped into a port, it
pushes on a plunger, thus extending
it. To return or retract a cylinder, oil
must be released to a reservoir. A
plunger returns either because of
the weight of a load or from some
mechanical force such as a spring.
•In mobile equipment, flow to and
from a single-acting cylinder is
controlled by a reversing directional
valve of a single-acting type.
b. Double-Acting Cylinder. This cylinder (Figure 4-2 must have ports at the
head and rod ends.
 Pumping oil into the head end moves a piston to extend a rod while any oil
in the rod end is pushed out and returned to a reservoir.
 To retract a rod, flow is reversed. Oil from a pump goes into a rod end, and a
head-end port is connected to allow return flow.
 The flow direction to and from a double-acting cylinder can be controlled by
a double-acting directional valve or by actuating a control of a reversible
pump.
Pneumatics
Pneumatic systems
 Pneumatic systems are designed to move loads by
controlling pressurized air in distribution lines and pistons
with mechanical or electronic valves.
 Air under pressure possesses energy which can be
released to do useful work.
 Examples of pneumatic systems: dentist’s drill, pneumatic
road drill, automated production systems.
Components of a Pneumatic System
 Compressor is the power source of a pneumatic system. It
is usually driven by a motor or an internal combustion
engine. The compressed air is first stored in a strong metal
tank called reservoir.
 Before entering the cylinders and valves, the compressed
air has to pass through the air treatment devices, including
air filter to remove dust and moisture, pressure regulator
to adjust pressure, and lubricator to spray lubrication oil
Air Filter -- to remove dust and
moisture
Pressure Regulator -- to adjust pressure
Lubricator -- to spray lubrication oil
Pneumatic Actuator -- Cylinder
Calculating the force produced by a
cylinder
Pressure Control Valve – Relieve Valve
Pressure Control Valve—Reduce Valve
Directional Control Valve – Two Port
Valve (2/2)
Directional Control Valve – Three Port
Valve (3/2)
Directional Control Valve – One Way
Valve
Directional Control Valve – Shuttle
Valve
Flow Control Valve – the Flow Regulator
Pneumatic Solenoid Valves